air bleeding SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 0B-7 Maintenance and Lubrication:
Brake Discs and Pads (Front) InspectionS6RW0D0206014
1) Remove wheel and caliper but don’t disconnect
brake hose from caliper.
2) Check front disc brake pads and discs for excessive
wear, damage and deflection. Replace parts as
necessary. For details, refer to “Front Disc Brake
Pad Inspection in Section 4B” and “Front Brake Disc
Inspection in Section 4B”.
Be sure to torque caliper pin bolts to specification.
Brake Drums and Shoes (Rear) InspectionS6RW0D0206015
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for
excessive wear and damage, while wheels and
drums are removed. At the same time, check wheel
cylinders for leaks. Replace these parts as
necessary.
For details, refer to “Rear Brake Drum and Shoe
Inspection in Section 4C”.
Brake Hoses and Pipes InspectionS6RW0D0206016
Perform this inspection where these is enough light and
use a mirror as necessary.
• Check brake hoses and pipes for proper hookup,
leaks, cracks, chafing and other damage.
• Check that hoses and pipes are clear of sharp edges
and moving parts.
Repair or replace any of these parts as necessary.
CAUTION!
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

Brake Fluid ReplacementS6RW0D0206017
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to “Air Bleeding of Brake
System in Section 4A”.
Brake Lever and Cable InspectionS6RW0D0206018
1) Inspect brake cable for damage and smooth
movement.
Replace cable if it is in deteriorated condition.
I3RM0A020006-01
I5RW0A020004-01
I4RS0A020008-01
I4RS0A020009-01

Downloaded from www.Manualslib.com manuals search engine 2C-7 Rear Suspension:
6) Connect rear height sensor link (if equipped) to rear
axle referring to “Height Sensor Removal and
Installation (If Equipped) in Section 9B”.
7) Install exhaust center pipe and muffler.
8) After installing removed parts, bleed air from brake
system referring to “Air Bleeding of Brake System in
Section 4A”. And then adjust parking brake cable
referring to “Parking Brake Inspection and
Adjustment in Section 4D”.
9) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
10) Lower hoist and bounce vehicle up and down
several times to stabilize suspension.
11) Tightening shock absorber lower nuts and rear axle
bolts to specified torque.
NOTE
When tightening these nuts and bolts, be
sure that vehicle is not on hoist and in
unloaded condition.

Tightening torque
Rear shock absorber lower nut: 90 N·m (9.0 kgf-
m, 65.0 lb-ft)
Rear axle bolt: 73 N·m (7.3 kgf-m, 53.0 lb-ft)
12) Perform brake test (foot brake and parking brake).
13) Check each installed parts for brake fluid leakage.
Rear Axle and Coil Spring InspectionS6RW0D2306009
• Inspect for cracks, deformation or damage.
• Inspect bushing for damage, wear or breakage.
Replace any defective part.
Rear Axle Bush InspectionS6RW0D2306010
Inspect for cracks, deformation or damage. If necessary,
replace rear axle assembly.
Rear Wheel Disc, Bolt and Bearing InspectionS6RW0D2306011
• Check tightness of wheel nuts and, if necessary,
retighten to specified torque.
• Check wheel disc deformation, damage, crack and
etc.
Replace defective disc with new one.
• Check installation face inside of wheel disc for rust.
As rust affects adversely, remove it thoroughly.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Check wear of wheel bearings. When measuring
thrust play, apply a dial gauge to axle shaft center.
When the thrust play exceeds limit, replace bearing.
Rear wheel bearing thrust play
Limit: 0.1 mm (0.004 in.)
• Check noise and smooth rotation of wheel by rotating
wheel. If it is defective, replace bearing.
(a)I5RW0A230022-01
I3RM0A230049-01
I3RM0A230050-01

Downloaded from www.Manualslib.com manuals search engine 2C-9 Rear Suspension:
Installation
1) Insert wheel stud bolt (1) in hub hole. Rotate wheel
stud bolt slowly to assure that serrations are aligned
with those made by original bolt.
2) Install brake back plate, rear wheel hub and new rear
wheel hub bolts and then tighten rear wheel hub
mounting bolts to specified torque.
CAUTION!
Use new rear wheel hub mounting bolts.

Tightening torque
Rear wheel hub mounting bolt: 73 N·m (7.3 kgf-
m, 53.0 lb-ft)
3) For 4WD model, install rear drive shaft referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
CAUTION!
Never reuse rear drive shaft nut.

Tightening torque
Drive shaft nut (a): 175 N·m (17.5 kgf-m, 127.0
lb-ft)4) Connect wheel speed sensor and tighten wheel
speed sensor bolt (2WD model) to specified torque.
Tightening torque
Wheel speed sensor bolt : 11 N·m (1.1 kgf-m, 8.0
lb-ft)
5) Connect brake pipe (1) to wheel cylinder and tighten
brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
6) Install brake drum referring to Step 1) and 2) of
“Installation” under “Rear Brake Drum Removal and
Installation in Section 4C”.
7) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation, see “Air Bleeding of
Brake System in Section 4A”.
8) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
9) Upon completion of all jobs, depress brake pedal
with about 300 N (30 kg, 66 lbs) load at least 3 times
so as to obtain proper drum-to-shoe clearance.
Adjust parking brake cable. For adjustment, see
“Parking Brake Inspection and Adjustment in Section
4D”.
10) Check to ensure that brake drum is free from
dragging and proper braking is obtained.
11) Perform brake test (foot brake and parking brake).
12) Check each installed part for fluid leakage.
1
I5JB0A220017-01
1,(a)
1
I7RW01230012-01
(a)
1
I5RW0A230018-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1
Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1
Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System
Construction (If Equipped) ................................ 4A-2
Front Brake Hose / Pipe Construction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4
Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7
Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-7
Brake Fluid Level Inspection ............................... 4A-8
Brake Light Switch Adjustment ........................... 4A-8
Air Bleeding of Brake System ............................. 4A-8
Front Brake Hose / Pipe Removal and
Installation ......................................................... 4A-9
Rear Brake Hose / Pipe Removal and
Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-10
Master Cylinder and Brake Booster
Components.................................................... 4A-11
Master Cylinder Reservoir Removal and
Installation ....................................................... 4A-11
Master Cylinder Removal and Installation......... 4A-12
Master Cylinder Inspection ............................... 4A-13
Booster Operation Inspection ........................... 4A-14
Brake Booster Removal and Installation ........... 4A-15
Brake Booster Inspection .................................. 4A-15
Booster Push Clevis Rod Adjustment ............... 4A-16
Specifications..................................................... 4A-16
Tightening Torque Specifications ...................... 4A-16
Special Tools and Equipment ........................... 4A-16
Recommended Service Material ....................... 4A-16
Special Tool ...................................................... 4A-16
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and
Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Caliper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and
Assembly........................................................... 4B-4
Front Disc Brake Caliper Inspection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .......................................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipment .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Drum Brake Components ...........................4C-1
Rear Brake Drum Removal and Installation ........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Shoe Removal and Installation ........4C-3
Rear Brake Shoe Inspection ...............................4C-4
Wheel Cylinder Removal and Installation ...........4C-4
Wheel Cylinder Inspection ..................................4C-5
Brake Back Plate Removal and Installation ........4C-5
Specifications .......................................................4C-6
Tightening Torque Specifications ........................4C-6
Special Tools and Equipment .............................4C-6
Recommended Service Material .........................4C-6
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1
Repair Instructions ..............................................4D-2
Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Lever Removal and Installation ....4D-3

Downloaded from www.Manualslib.com manuals search engine 4A-7 Brake Control System and Diagnosis:
Repair Instructions
Brake Pedal ComponentsS6RW0D4106018
CAUTION!
If equipped Brake Pedal Foot Protection
System, never disassemble brake pedal
assembly. Disassemble will spoil its original
function. If faulty condition is found, replace
it with new one.

Brake Pedal Free Height InspectionS6RW0D4106001
1) Check brake pedal free height. If it is not within
specification, check and adjust following item 2) and
6).
Brake pedal free height “a” from carpet
111 – 131 mm (4.4 – 5.1 in.)
2) Check measurement between booster mounting
surface and center of clevis pin hole. When booster
push rod clevis has been reinstalled, it is important
that the measurement is adjusted (refer to “Brake
Booster Inspection”).
3) Check brake light switch position. Adjust it if it is out
of specification.
4) Check pedal for dent.
5) Check brake booster for installation.6) Check brake booster push rod for length.
Brake Pedal Play InspectionS6RW0D4106002
Pedal play should be within the following specification. If
out of specification, check brake light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and booster clevis pin
installation for looseness and replace if defective.
Brake pedal play
“a”
: 1 – 8 mm (0.04 – 0.31 in.)
Excessive Pedal Travel InspectionS6RW0D4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300
N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance is
out of specification, possible causes are as follows.
If clearance “a” is less than specification, the most
possible cause is that air is in lines or brake fluid
leakage.
Should clearance “a” remain less than specification
even after bleeding of system, other possible but
infrequent cause is malfunction of booster push rod
length out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of
Brake System”.
Brake pedal arm to wall clearance
“a”
When pedal is depressed at 300 N (30 kg, 66 lbs)
: Over 40 mm (1.57 in.)
[A]: A/T model : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
1. Brake pedal : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)
2. Brake pedal bracket
I6RW0C410004-01
I6RW0C410005-01
“a”I3RH0A410010-01
I6RW0C410006-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-8
Brake Fluid Level InspectionS6RW0D4106004
CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning light lights sometimes
during driving, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

1) Check master cylinder, reservoir and reservoir hose
(if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX (1) and
MIN marks (2) on reservoir.
Brake Light Switch AdjustmentS6RW0D4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and brake light
switch
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
Air Bleeding of Brake SystemS6RW0D4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper or wheel cylinder farthest from
master cylinder and then at front caliper of
the same brake line. Do the same on the
other brake line.

1
2
I7RW01410004-01
1. Right front brake caliper 3. Right rear wheel cylinder
2. Left front brake caliper 4. Left rear wheel cylinder
I5RW0A410005-01
I7RW01410005-01

Downloaded from www.Manualslib.com manuals search engine 4A-9 Brake Control System and Diagnosis:
1) Fill master cylinder reservoir with specified brake
fluid and keep at least one-half full of fluid during
bleeding operation.
Brake fluid
: Refer to reservoir cap
2) Remove bleeder plug cap. Attach a vinyl tube to
bleeder plug, and insert the other end into container.
3) Depress brake pedal several times, and then while
holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cylinder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air
bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake pedal
and tighten bleeder plug.
Tightening torque
Front brake caliper bleeder plug: 9 N·m (0.9 kgf-
m, 6.5 lb-ft)
Rear wheel cylinder bleeder plug: 8 N·m (0.8
kgf-m, 6.0 lb-ft)
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid
pressure to pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level
referring to “Brake Fluid Level Inspection”.
10) Check brake pedal for sponginess. If found spongy,
repeat entire procedure of bleeding.
Front Brake Hose / Pipe Removal and
Installation
S6RW0D4106007
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and
wheel.
NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign material from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wheel is in straight-forward
position and flexible hose has not twist or kink.
• Install clamps and tighten nuts referring to “Front
Brake Hose / Pipe Construction”.
• Install brake flexible hose (1) to caliper as shown in
figure.
Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
I2RH01410016-01
I2RH01410017-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-10
• Check to make sure that flexible hose doesn’t contact
any part of suspension, both in extreme right and
extreme left turn conditions. If it does at any point,
remove and correct. Fill and maintain brake fluid level
in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake
System”.
• Perform brake test and check installed part for fluid
leakage.
Rear Brake Hose / Pipe Removal and
Installation
S6RW0D4106008
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and
wheel.
2) Clean dirt and foreign material from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Install clamps and tighten nuts referring to “Rear
Brake Hose / Pipe Construction”.
• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake
System”.
• Perform brake test and check each installed part for
fluid leakage.
• When installing hose, make sure that it has no twist or
kink.
Brake Hose and Pipe InspectionS6RW0D4106009
Hose
The brake hose assembly should be checked for road
hazard damage, for cracks and chafing of outer cover,
for leaks and blisters. A light and mirror may be needed
for an adequate inspection. If any above conditions are
observed on brake hose, it is necessary to replace it.
Pipe
Inspect the pipe for damage, cracks, dents and
corrosion. If any defect is found, replace it.
2. Location mark
3. Outside of vehicle
4. Inside of vehicle
I7RW01410007-02
I5RW0A410007-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-12
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Remove reservoir connector pin (1) by using special
tool and then reservoir.
Special tool
(A): 09916–44310
Installation
1) When using new grommets (2), lubricate them with
the same fluid as the one to fill reservoir with.
Then press-fit grommets (2) to master cylinder (3).
2) Install reservoir (1) to master cylinder.
3) Drive in reservoir connector pin (2) by using special
tool (A). Till both of its ends at the right and left of
reservoir (1) becomes the same length.
Special tool
(A): 09916–44310 4) Connect clutch reservoir hose to reservoir (M/T
model).
5) Connect fluid level switch coupler (1) and clamp (3)
to reservoir (2).
6) Fill reservoir with specified brake fluid up to its MAX
level.
7) After completing the work, bleed air from brake
system referring to “Air Bleeding of Brake System”
and bleed air from clutch system referring to“Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check each installed parts for fluid leakage.
9) Perform brake test and check fluid leakage.
Master Cylinder Removal and InstallationS6RW0D4106012
Removal
CAUTION!
• Never disassemble master cylinder since
the master cylinder is supplied as
assembly parts.
If faulty condition is found, replace it with
new one.
• Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be
damaged by brake fluid, flush it with water
immediately if any fluid is spilled.

1) Clean outside of master cylinder.
2) Disconnect fluid level switch coupler (1) and clamp
(3) from reservoir (2).
1 (A)I5JB0A410013-02
1
2
2
3
I7RW01410010-02
I7RW01410011-01
2
13
I7RW01410009-01
2
13
I7RW01410009-01

Downloaded from www.Manualslib.com manuals search engine 4A-13 Brake Control System and Diagnosis:
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Disconnect brake pipes (1) connected to master
cylinder.
6) Remove master cylinder fixing nuts (2).
7) Remove master cylinder (3) and O-ring.
Installation
1) Install new O-ring (2) to master cylinder assembly
(1).
2) Apply grease to piston rod “A”.
Use specified grease in spare to master cylinder or
brake booster as supply parts.
3) Install master cylinder assembly (1) to brake booster
(3) and tighten master cylinder fixing nuts to
specified torque.
Tightening torque
Master cylinder fixing nut (a): 18 N·m (1.8 kgf-
m, 13.0 lb-ft)4) Connect brake pipe to master cylinder and tighten
flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
5) Connect clutch reservoir hose to reservoir and install
reservoir hose clamp (M/T model).
6) Connect fluid level switch connector and clamp.
7) Fill reservoir with specified brake fluid up to its MAX
level.
8) After completing the work, bleed air from brake and
clutch system referring to “Air Bleeding of Brake
System” and bleed air from clutch system referring to
“Air Bleeding of Clutch System in Section 5C” (M/T
model).
9) Check each installed parts for fluid leakage.
10) Check brake pedal for play referring to “Brake Pedal
Play Inspection”.
11) Perform brake test and check fluid leakage.
Master Cylinder InspectionS6RW0D4106013
• Depress brake pedal a few times and retain brake
pedal. If pedal gone down, replace the brake master
cylinder assembly.
• Check master cylinder for leakage, corrosion and
smooth operation.
• Inspect distance “a” to be the following.
If measurement is out of specification, replace master
cylinder assembly.
Distance
“a”: 72.0 mm (2.83 in.) or more
2
1
3I7RW01410012-01
(a)3
2
1
"A"
I7RW01410019-01
(a)I7RW01410013-01
I7RW01410014-01